Translating cavity valve

ABSTRACT

A valve assembly includes a valve body and an opening extending through the valve body along a longitudinal axis. The valve assembly also includes a valve member arranged within the opening, the valve member being movable, along the longitudinal axis, between an open position and a closed position. The valve assembly includes an upper seal positioned to seal against at least a first portion of the valve body. The valve assembly includes a lower seal positioned to seal against at least a second portion of the valve body, wherein both the upper seal and the lower seal travel with the valve member as the valve member moves between the open position and a closed position.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of co-pending U.S.Provisional Application Ser. No. 62/846,503 filed May 10, 2019 titled“TRANSLATING CAVITY VALVE,” the full disclosure of which is herebyincorporated herein by reference in its entirety for all purposes.

BACKGROUND 1. Field of Disclosure

This disclosure relates in general to oil and gas tools, and inparticular, to valves for controlling fluid flow.

2. Description of the Prior Art

In oil and gas production, valves may be used to regulate the flow offluids through one or more wellbore tubulars. In certain applications,the fluid may include particulates, such as proppant in hydraulicfracturing operations. As the valves are cycled, a valve cavity maychange in volume, providing additional area that may be infiltrated andfilled with particulates, which may make future operation of the valvechallenging. Furthermore, various sealing surfaces and/or seals may beexposed to the particulates, which could damage the seals and lead toleaks.

SUMMARY

Applicant recognized the problems noted above herein and conceived anddeveloped embodiments of systems and methods, according to the presentdisclosure, for valves and valve assemblies.

In an embodiment, a valve assembly includes a valve body and an openingextending through the valve body along a longitudinal axis. The valveassembly also includes a valve member arranged within the opening, thevalve member being movable, along the longitudinal axis, between an openposition and a closed position. The valve assembly includes an upperseal positioned within a top seal orifice formed in the valve member,the upper seal positioned to seal against at least a first portion ofthe valve body. The valve assembly includes a lower seal positionedwithin a bottom seal orifice formed in the valve member, the lower sealpositioned to seal against at least a second portion of the valve body,wherein both the upper seal and the lower seal travel with the valvemember as the valve member moves between the open position and a closedposition, the upper seal and a lower seal defining a cavity thatmaintains a substantially constant value throughout movement of thevalve member.

In an embodiment, a valve assembly includes a valve body, the valvebodying having a flow bore extending along a flow bore axis. The valveassembly also includes an opening extending through the valve body alonga longitudinal axis, the opening intersecting the flow bore. The valveassembly further includes a valve member positioned within the opening,the valve member being movable between an open position that aligns aflow passage with the flow bore and a closed position that aligns ablock with the flow bore. The valve assembly includes a cavity definedby an upper seal of the valve member and a lower seal of the valvemember, the cavity being translatable along the longitudinal axis inresponse to movement of the valve, the upper seal and lower seal eachengaging the valve body to block fluid ingress into the opening.

In an embodiment, a method for forming a translating cavity valveincludes providing a valve body having an opening that intersects a flowbore. The method also includes providing a valve member, the valvemember having an upper seal and a lower seal arranged at opposing endsof the valve member, a flow passage being between the upper seal and thelower seal. The method further includes arranging the valve memberwithin the opening. The method also includes engaging the valve bodywith the upper seal and the lower seal to from a cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

The present technology will be better understood on reading thefollowing detailed description of non-limiting embodiments thereof, andon examining the accompanying drawings, in which:

FIG. 1 is a schematic cross-sectional view of an embodiment of a valveassembly having an actuator, in accordance with embodiments of thepresent disclosure;

FIG. 2 is a sectional perspective view of an embodiment of a valveassembly, in accordance with embodiments of the present disclosure;

FIG. 3 is a cross-sectional perspective view of an embodiment of a valveassembly, in accordance with embodiments of the present disclosure;

FIGS. 4A and 4B are cross-sectional side views of an embodiment of avalve assembly illustrating a translating cavity, in accordance withembodiments of the present disclosure;

FIG. 5 is a sectional perspective view of an embodiment of a valveassembly, in accordance with embodiments of the present disclosure; and

FIG. 6 is a cross-sectional side view of an embodiment of a valveassembly and seal integrity system, in accordance with embodiments ofthe present disclosure.

DETAILED DESCRIPTION

The foregoing aspects, features and advantages of the present technologywill be further appreciated when considered with reference to thefollowing description of preferred embodiments and accompanyingdrawings, wherein like reference numerals represent like elements. Indescribing the preferred embodiments of the technology illustrated inthe appended drawings, specific terminology will be used for the sake ofclarity. The present technology, however, is not intended to be limitedto the specific terms used, and it is to be understood that eachspecific term includes equivalents that operate in a similar manner toaccomplish a similar purpose.

When introducing elements of various embodiments of the presentdisclosure, the articles “a,” “an,” “the,” and “said” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements. Anyexamples of operating parameters and/or environmental conditions are notexclusive of other parameters/conditions of the disclosed embodiments.Additionally, it should be understood that references to “oneembodiment”, “an embodiment”, “certain embodiments,” or “otherembodiments” of the present disclosure are not intended to beinterpreted as excluding the existence of additional embodiments thatalso incorporate the recited features. Furthermore, reference to termssuch as “above,” “below,” “upper”, “lower”, “side”, “front,” “back,” orother terms regarding orientation are made with reference to theillustrated embodiments and are not intended to be limiting or excludeother orientations. Moreover, like reference numerals may be used forlike items throughout the specification, however, such usage is forconvenience and is not intended to limit the scope of the presentdisclosure.

Embodiments of the present disclosure include a valve, such as a gatevalve, with a significantly reduced cavity. Moreover, the cavity remainsconstant throughout the travel of the gate. Additionally, the valve iscapable of having a double barrier for increased safety and longevity.The sealing mechanism for the valve is relocated to the valve gate, andtravels with the gate throughout the stroke of the gate. The resultingcavity therefore translates with the gate relative to the valve body. Bydecreasing the valve cavity, there is less ingress of material into thecavity. Ingress often results in problems for the valve operation, forexample in fracturing operations. With the reduced cavity volume, fewerconsumables like grease are needed, saving costs. Cost reduction is alsoprovided by a reduction in ingress of materials, along with the reducedcost of consumables. Furthermore, in various embodiments, valves may beconfigured with reduced valve block size for large bore valves.

Embodiments are directed toward valves, which may be referred to astranslating cavity valves or valve assemblies that include a cavity thatremains substantially constant throughout a stroke of the valves. As aresult, changes in cavity volume are eliminated or reduced to improveoperation of the valve. In various embodiments, the valve furtherincludes seals arranged on a valve member, which may be a gate inillustrated embodiments, which also translate along with movement of thevalve gate along an axis. The seals may be positioned such that voids inthe valve are substantially isolated from the valve working fluid, whichmay include particulates, which may cause damage to the valve, such asto the seals or sealing surfaces. Embodiments may also include a bypassthat extends longitudinally through the valve member, for exampleperpendicular to a valve opening, to equalize pressure across the valveand enable movement between an open position and a closed position. Itshould be appreciated that, in various embodiments, the valve may beconfigured to operate without stem packing and/or using the stem packingas a backup or redundancy. Furthermore, in various embodiments, thevalve may be configured to include one or more ports for leak detectionbetween sealing assemblies within the valve.

FIG. 1 is a cross-sectional side elevation view of an embodiment of avalve assembly 100 that includes an actuator 102 coupled to a bonnet104. It should be appreciated that while the illustrated actuator 102 isan automated or controlled actuator, that manual operators may also beutilized within the scope of the present disclosure. The illustratedactuator 102 is coupled to a valve stem 106, via a connector 108 thatextends through a central bore and couples to a valve member 110arranged within a chamber 112. The illustrated valve member 110 includesa passage 114 and a block 116. As shown, fluid (e.g., gas, liquid,solid, or a combination thereof) may enter the valve 100 through aninlet passage 118 and engage the valve member 110 en route to an outletpassage 120. In the illustrated embodiment, the valve member 110 istransitioning between an open position, in which the passage 114 issubstantially aligned with the inlet passage 118 and the outlet passage120, and a closed position, in which the block 116 is substantiallyaligned with the inlet passage 118 and the outlet passage 120. Theillustrated valve member 110 may seal against valve seats 122.

In operation, a bore 124 extends through a valve body 126 along a valvebody axis 128. The fluid is at a pressure and travels through the bore124, for example, when the valve member 110 is positioned in an openposition. In certain operations, such as fracturing operations, thefluid may include particulates, such as proppant, that may erodesections of the valve body 126, for example, along the bore 124.Additionally, the fluid may contain corrosive materials and be at a highpressure, which may further damage the valve body 126.

In certain embodiments, the fluid may leak or otherwise be directed intothe chamber 112, where the particulates within the fluid may collect.This may result in a restriction to valve movement, which mayundesirably hinder cycling of the valve. As a result, the valve may notfully open or fully close, which may lead to operational upsets.

FIG. 2 is a sectional perspective view of a valve assembly 200, whichmay also be referred to as a translating cavity valve assembly. Itshould be appreciated that like reference numerals may be used betweenfigures for clarity and conciseness, but such use should not beinterpreted as limiting components between embodiments. The illustratedvalve assembly 200 has several features that have been removed forclarity with the following discussion, such as the valve stem 106,actuator 102, and the like.

The illustrated valve assembly 200 includes the valve member 110 withinan oblong opening 202 formed in the valve body 126. The illustratedvalve member 110 is shown with hidden lines and in sectional view inorder to illustrate various features that will be described herein. Itshould be appreciated that the shape of the valve member 110 and/or theopening 202 may be particularly selected based on expected operatingconditions and that the illustration of oblong components is notintended to be limiting. The valve member 110, which is a gate in theillustrated embodiment, is positioned within the opening 202 is arrangedto translate along a longitudinal axis 204 of the valve body 126 totransition a passage 114 between a closed position (illustrated) and anopen position (not illustrated). It should be appreciated that othervalve members may also be utilized with embodiments of the presentdisclosure. As noted above, in operation, fluid, which may be a gas,liquid, solid, or combination thereof, flows through the inlet 118 (notpictured) of the valve body 126 toward the valve member 110. When theflow passage 114 is aligned with the inlet 118, flow may continuethrough the valve assembly, as opposed to when the block 116 is alignedwith the inlet 118, as shown in FIG. 2.

In the illustrated embodiment, the valve seats 122 extend into theopening 202 to engage at least a portion of the valve member 110. Forexample, as the valve member 110 translates along the axis 204 withinthe oblong opening 202, various portions of the valve member 110 maycontact the respective valve seats 122. Traditional valves may includeone or more seals arranged along the valve body and/or the valve seats.However, as will be described below, embodiments of the presentdisclosure include seals arranged along the valve member 110, whichenables a substantially constant cavity that translates with the valvemember 110.

In the illustrated embodiment, the valve member 110 includes a top sealorifice 206 and a bottom seal orifice 208. In various embodiments, sealsare arranged within the respective orifices (not pictured) to bearagainst at least a portion of the valve body 126. The seals may beformed from any reasonable material, such as a metal, a composite, apolymer, or a combination thereof, to block ingress of fluid.

The top seal orifice 206 is arranged axially higher (along the axis 204)than the flow passage 114 and the bottom seal orifice 208 is arrangedaxially lower (along the axis 204) than the flow passage 114 and theoutlet passage 120 of the valve body 126. As will be described below, invarious embodiments movement of the valve member 110 between the openposition and the closed position may also lead to movement of the topand bottom seal orifices 206, 208. During this movement, the top andbottom seal orifices 206, 208 may be positioned such that they do notcross or otherwise interact with the inlet 118 or outlet 120 of thevalve body 126 and/or with the valve seats 122. As a result, the sealsassociated with the top and bottom seal orifices 206, 208 may sealagainst the valve body 126 throughout movement of the valve member 110.As will be described, such an arrangement may create a translatingcavity, which may reduce the ingress of fluid and/or particulates intothe chamber 112.

The illustrated valve member 110 further includes a bypass 210 extendingthrough an axial length 212 of the valve member 110 to providecommunication between a lower void 214 and an upper void 216. Such abypass enables pressure equalization to facilitate axial translation ofthe valve member 110. It should be appreciated that each of the lowervoid 214 and the upper void 216 may be in fluid communication with thechamber 112.

The illustrated bypass 210 is shown positioned radially inward from anouter diameter 218 of the valve member 110. In other words, the bypass210 does not interact with the orifices 206, 208. Furthermore, in theillustrated embodiment, the bypass 210 does not intersect the passage114. However, it should be appreciated that, in various embodiments, thebypass 210 may intersect the passage 114.

FIG. 3 is cross-sectional perspective view of an embodiment of the valveassembly 200 illustrating the valve member 110 arranged within theopening 202. In the illustrated embodiment, the valve member 110 isshown in the closed position where the block 116 is aligned with theinlet passage 118 and the outlet passage 120. As a result, fluid flowthrough the valve is blocked. As noted above, the valve member 110 mayseal or otherwise contact against the valve seats 122.

The illustrated embodiments includes a cavity 300, which may be definedas a volume between an upper seal 302 associated with the top sealorifice 206 and a bottom seal 304 associated with the bottom sealorifice 208. In other words, the cavity 300 is represented by a volumebetween sealing surfaces within the valve. In a traditional valve, thecavity may extend all the way up to a stem packing, and as a result,movement of the valve member within the opening would change a volume ofthe seal as the stem packing moves and/or as the valve member moves. Inother words, the stem penetrates between the sealing elements. However,embodiments of the present disclosure eliminate this concern and enablea substantially constant cavity 300.

In the illustrated embodiment, the upper seal 302 and lower seal 304 arearranged to circumferentially surround the valve member 110. As aresult, a seal is formed around an entirely of the valve member 110, forexample, as the valve member 110 contacts the valve body 126. As notedabove, the seals 302, 304 can be formed from any reasonable material andmay extend outward from the respective orifices to engage the valve body126. It should be appreciated that FIG. 3 may illustrate single seals atthe top and bottom of the valve member 110, but it should be appreciatedthat multiple seals may be incorporated into various embodiments.

The valve member 110 further includes a top bevel 306 and a bottom bevel308. The illustrated bevels 306, 308 are axially higher and axiallylower, respectively, of the top and bottom seal orifices 206, 208. Thatis, the top bevel 306 is axially higher than the top seal orifice 206and the bottom bevel 308 is axially lower than the bottom seal orifice208. The illustrated bevels 306, 308 include respective slanted faces310, 312 positioned at angles 314, 316. It should be appreciated thatthe angles 314, 316 may be different between the top bevel 306 and thebottom bevel 308. Furthermore, respective axial lengths 318, 320 of thebevels 306, 308 may also be different. However, in other embodiments,the bevels 306, 308 may be substantially similar. Furthermore, it shouldbe appreciated that the bevels 306, 308 may not be present in otherembodiments, or different shapes or sized bevels or cutouts may bepresent.

As shown in the embodiment illustrated in FIG. 3, the upper seal 302contacts the valve body 126 and the lower seal 304 also contacts thevalve body 126. The lower seal 126 is in contact axially lower than thevalve seat 122. As a result, particulates may be blocked from flowingtoward the lower void 214, which could build up and make operation ofthe valve difficult.

In various embodiments, a bonnet gasket seal (not pictured) may bepositioned within a groove 322 formed in the valve body 126. This sealmay be a secondary seal or backup seal when utilizing embodiments of thepresent disclosure because pressure is substantially contained with theseals 302, 304 defining the cavity. This backup sealing capability mayprovide various advantages with maintenance, operation, and repair, asdescribed herein.

FIGS. 4A and 4B are cross-sectional views of an embodiment of the valveassembly 200 where the valve member 110 is arranged within the opening202. FIG. 4A illustrates the valve member 110 in the closed positionwhere the block 116 is aligned with the inlet and outlet passages 118,120. The cavity 300 is shown between the upper seal 302 and the lowerseal 304. In the illustrated embodiment, both the upper seal 302 and thelower seal 304 engage the valve body 126. As previously noted, the lowerseal 304 is axially lower than the valve seat 122, and in variousembodiments, it arranged along the valve member 110 such that the lowerseal 304 does not engage and/or pass the valve seat 122. In other words,the lower seal 304 may be positioned to remain within the lower void214.

Movement of the valve member 110 to the open position will also drivemovement of the cavity 300 as the valve member 110 axially translateswithin the opening 202. As a result, volume is not added or removed fromthe cavity 300 during movement of the valve member 110, as illustratedin FIG. 4B, where the valve member 110 is translated to the openposition to align the passage 114 with the inlet and outlet passages118, 120. In the illustrated embodiments, the seals 302, 304 maintaincontact with the valve body 126, and in certain embodiments, may engagethe valve seats 122. Accordingly, there may be reduced ingress ofmaterials, such as particulates. Additionally, in various embodiments,because the upper and lower seals 302, 304 maintain the operatingpressure, other pressures found outside the seals may be vented or thearea may be cleaned without disconnecting the valve from service.

FIG. 5 is a perspective view of an embodiment of the valve assembly 200illustrating the valve member 110 in the open position where the flowpassage 114 is aligned with the inlet and outlet passages 118, 120. Itshould be appreciated that the configuration shown in FIG. 5 differsfrom the configuration in at least FIG. 2 because the flow passage 114is axially lower than the block 116. As previously noted, the upper andlower seals 302, 304 seal against the valve body 126 in variousembodiments. However, it should be appreciated that configurations, suchas those shown in FIG. 5, may further enable sealing against the bonnet104.

Further illustrated is the bypass 210 extending between the lower void214 and the upper void 216. As described above, the bypass enablespressure equalization across the valve member 210 to facilitate axialmovement between the open position and the closed position. As shown,the voids 214, 216 are in fluid communication with one another. Theillustrated bypass 210 does not intersect the passage 114 and isarranged within the outer diameter 218 of the valve member 110. As aresult, the bypass 210 does not break or otherwise affect the sealing ofthe upper and lower seals 302, 304.

FIG. 6 is a cross-sectional side view of an embodiment of the valveassembly 200 that includes a seal integrity detection system 600. Theillustrated embodiment includes the upper and lower seals 302, 304 ofthe valve member 110 engaging the valve body 126 to form the cavity 300.Further illustrated is the valve stem 106 extending through the bonnet104. However, it should be appreciated that, in other embodiments, thevalve stem 106 may extend through an extension of the valve body 126and/or at least partially through an actuator body. The illustrated stem106 includes stem packing 602 arranged within the bonnet 104. In variousembodiments, the stem packing 602 may be removed as containment isprovided by the upper seal 302 and the lower seal 304. However, in otherembodiments, the stem packing 602 may be utilized as a secondary orredundant seal.

In the illustrated embodiment, a pressure transducer 604 is positionedto detect pressure between the upper seal 302 and the stem packing 602.If the pressure transducer 604 detects pressure above a threshold amount(e.g., an amount set by an operator), that reading may be indicative ofdamage to the upper seal 302 and/or the lower seal 304. It should beappreciated that damage to the lower seal 304 may still be recognizeddue to the bypass 210 (not pictured) extending through the valve member110. Accordingly, the operating integrity of the seals 302, 304 may beevaluated throughout working conditions. The use of the redundant stempacking 602 may allow operations to continue, even if damage to theupper or lower seals 302, 304 is detected, and to thereafter providemaintenance operations later. Furthermore, if the upper and lower seals302, 304 maintain sealing capability, the valve may be utilized in otherjobs, thereby saving costs.

In certain embodiments, the seal integrity system 600 may include one ormore alarms or indicators to provide a notification to operators. Forexample, the pressure transducer 604 may transmit a signal to acontroller that receives and interprets the reading and correlates thedata to a pressure. The pressure may be evaluated against a thresholdamount, which may be particularly selected based on operatingconditions, where a pressure that exceeds the threshold amount maytrigger an alarm or notification. In this manner, seal integrity may becontinuously monitored.

Although the technology herein has been described with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent technology. It is therefore to be understood that numerousmodifications may be made to the illustrative embodiments and that otherarrangements may be devised without departing from the spirit and scopeof the present technology as defined by the appended claims.

1. A valve assembly, comprising: a valve body; an opening extendingthrough the valve body along a longitudinal axis; a valve memberarranged within the opening, the valve member being movable, along thelongitudinal axis, between an open position and a closed position; anupper seal positioned within a top seal orifice formed in the valvemember, the upper seal positioned to seal against at least a firstportion of the valve body; and a lower seal positioned within a bottomseal orifice formed in the valve member, the lower seal positioned toseal against at least a second portion of the valve body, wherein boththe upper seal and the lower seal travel with the valve member as thevalve member moves between the open position and a closed position, theupper seal and a lower seal defining a cavity that maintains asubstantially constant value throughout movement of the valve member. 2.The valve assembly of claim 1, wherein the lower seal has a range oftravel that is axially lower than a vertical position of a valve seat.3. The valve assembly of claim 1, wherein the upper seal has a range oftravel that is axially higher than a vertical position of a valve seat.4. The valve assembly of claim 1, further comprising: a bypass endingthrough an axial length of the valve member, the bypass fluidly couplinga lower void and an upper void arranged at different ends of theopening.
 5. The valve assembly of claim 4, wherein the bypass isarranged within an outer diameter of the valve member, the bypass beingfluidly isolated from a flow passage extending through the valve member.6. The valve assembly of claim 1, further comprising: a seal integritysystem, the seal integrity system obtaining a pressure reading for avolume between the upper seal and a stem packing, the seal integritysystem identifying a leak in the upper seal when the pressure readingexceeds a threshold.
 7. The valve assembly of claim 1, furthercomprising: a top bevel arranged axially higher than the upper seal, thetop bevel having an upper slanted face extending radially outward fromthe longitudinal axis; and a bottom bevel arranged axially lower thanthe lower seal, the bottom bevel having a lower slanted face extendingradially outward from the longitudinal axis.
 8. The valve assembly ofclaim 1, wherein the valve member is oblong shaped.
 9. A valve assembly,comprising: a valve body, the valve bodying having a flow bore extendingalong a flow bore axis; an opening extending through the valve bodyalong a longitudinal axis, the opening intersecting the flow bore; avalve member positioned within the opening, the valve member beingmovable between an open position that aligns a flow passage with theflow bore and a closed position that aligns a block with the flow bore;and a cavity defined by an upper seal of the valve member and a lowerseal of the valve member, the cavity being translatable along thelongitudinal axis in response to movement of the valve, the upper sealand lower seal each engaging the valve body to block fluid ingress intothe opening.
 10. The valve assembly of claim 9, wherein a cavity volumeis substantially constant throughout movement of the valve member. 11.The valve assembly of claim 9, wherein the upper seal is arranged withina top seal orifice formed in the valve member and the lower seal isarranged within a bottom seal orifice formed in the valve member. 12.The valve assembly of claim 9, wherein a first sealing plane of theupper seal is non-intersecting with a valve seat.
 13. The valve assemblyof claim 12, wherein a second sealing plane of the lower seal isnon-intersecting with the valve seat.
 14. The valve assembly of claim 9,further comprising: a bypass ending through an axial length of the valvemember, the bypass fluidly coupling a lower void and an upper voidarranged at ends of the opening.
 15. The valve assembly of claim 14,wherein the bypass is arranged within an outer diameter of the valvemember, the bypass being fluidly isolated from the flow passage.
 16. Thevalve assembly of claim 9, further comprising: a top bevel arrangedaxially higher than the upper seal, the top bevel having an upperslanted face extending radially outward from the longitudinal axis; anda bottom bevel arranged axially lower than the lower seal, the bottombevel having a lower slanted face extending radially outward from thelongitudinal axis.
 17. The valve assembly of claim 9, furthercomprising: a seal integrity system, the seal integrity system obtaininga pressure reading for a volume between the upper seal and a stempacking, the seal integrity system identifying a leak in the upper sealwhen the pressure reading exceeds a threshold.
 18. A method for forminga translating cavity valve, comprising: providing a valve body having anopening that intersects a flow bore; providing a valve member, the valvemember having an upper seal and a lower seal arranged at opposing endsof the valve member, a flow passage being between the upper seal and thelower seal; arranging the valve member within the opening; and engagingthe valve body with the upper seal and the lower seal to from a cavity.19. The method of claim 18, further comprising: forming a top sealorifice in the valve member, the top seal orifice receiving the upperseal; and forming a bottom seal orifice in the valve member, the bottomseal orifice receiving the lower seal.
 20. The method of claim 18,wherein the cavity moves along with the valve member as the valve membermoves between an open position and a closed position.